Junction box construction for use in curved structures

ABSTRACT

A method and components for adapting a standard rectangular or other pre-existing junction box for mounting within cylindrical concrete piers and other curved structures commonly employed for supporting light poles and other mechanisms wherein the front wall portion of the adapted junction box and the face plate member associated therewith for controlling access to the interior portion of the junction box are both shaped and configured to conform to the specific curvature associated with the outer surface of the curved structure into which the adapted junction box will be mounted. The present components enable the adapted junction box to be completely embedded within the curved structure such that the exposed front wall portion thereof including the face plate member lie substantially flush with the outer surface of the curved retaining structure. Although a generally rectangularly shaped junction box can be easily adapted for substantially flush mounting within a curved structure, the present adapter components will likewise work equally as well with other junction box configurations including junction boxes having a curved front wall portion already associated therewith to produce an overall assembly having a front wall portion that is compatible with the curvature of the outer surface of the particular curved structure into which it will be encased. The present adaptation allows more convenient access to the interior portion of the junction box and provides a more weatherproof and tamperproof junction box as compared to the known square or rectangularly shaped junction boxes which are often times used in curved structure applications.

This application is a continuation-in-part of application Ser. No.08/316,944, filed Oct. 3, 1994, now U.S. Pat. No. 5,553,730.

The present invention relates to means for adapting a standardrectangular or other pre-existing junction box for flush embedmentwithin curved structures. More particularly, standard rectangularelectrical junction boxes or other pre-existing junction boxes, such asjunction boxes for controls for plumbing, gas, or other applications,may be adapted by means of curved adapter frame or adapter segmentdevices engaged with or attached to the front portion of the junctionbox to permit the embedded flush mounting of the assembled constructionwithin cylindrical concrete piers or other curved structures, such aspiers typically used for holding and supporting light poles and otherstructures that require electrical wiring and other electricalcomponents to be associated therewith.

BACKGROUND OF THE INVENTION

Electrical junction boxes are generally formed as box-like structures,such as the known, standard rectangular, square, round, and octagonalshaped steel and PVC junction boxes commonly employed in many differentapplications, which applications often include the surface or flushmounting of such junction boxes on a planar wall, either interiorly orexteriorly. Significantly, a flush mounting within curved structuressuch as cylindrical concrete piers is not realizable with the standardjunction boxes, and on those occasions when rectangular, square, round,or octagonal shaped junction boxes have been either attached to orencased within concrete piers, unique problems have arisen. For example,in such situations, installed standard junction boxes have sometimesbeen completely recessed within the curved structure so as to preventany portion thereof from protruding beyond the outer surface of thecurved structure. While this arrangement of the junction box within thecurved retaining structure helps to prevent mechanical or environmentaldamage to the junction box, it also makes access to and work within thejunction box more inconvenient and difficult. Alternatively, suchjunction boxes, or portions thereof, have been installed to protrudebeyond the outer surface of the curved structure into which they aremounted, making access to and work within the boxes more convenient, butsuch arrangement leaves portions of the junction boxes more vulnerableto damage from external sources. The latter configuration is also lessweatherproof and tamperproof than is generally desired. Thus, there is aneed for means to adapt standard junction boxes for flush mounting incylindrical or curved shaped structures of various sizes, such as incylindrical concrete piers commonly used for supporting light poles andother structures.

Co-pending U.S. patent application Ser. No. 08/316,944, now U.S. Pat.No. 5,553,730, previously filed by this Applicant, discloses a junctionbox specifically configured for flush mounting within a curvedstructure, which junction box has a curvilinear or arcuate shaped frontwall portion that is specifically designed to match the curvature of thecurved structures, such as cylindrical concrete piers. That junction boxconstruction is intended to replace the conventional rectangular and/orsquare shaped junction boxes for mounting applications within a curvedstructure. While such a construction is quite advantageous, the plethoraof differently sized curved structures with which the junction boxes maybe employed results in a need to keep an inventory of junction boxesthat have different front wall curvatures. Keeping a large inventory ofdifferent junction boxes, however, can be costly and can requiresignificant storage space.

Until now, there has been no known means for adapting a conventional orstandard junction box for flush mounting within a curved structured orfor adapting a junction box having an arcuate shaped front wall portionfor flush mounting within a curved structure that has a curvaturedifferent from that of the curved junction box. Although many of theknown prior art devices, including the devices disclosed in co-pendingU.S. application Ser. No. 08/316,944, now U.S. Pat. No. 5,553,730 havedifferent box-like shapes, no known prior art devices have includedmeans for making standard non-curvilinear or non-arcuate shaped junctionboxes compatible for ready use in a wide variety of differently curvedstructures, such as cylindrical concrete piers. Consequently, for theseand other reasons, the constructions of this application offersignificant advantages in applications where it is desirable to adapt apre-existing or standard junction box for flush mounting within a curvedstructure, especially since they permit the advantages realized by thejunction boxes of co-pending application Ser. No. 08/316,944 now U.S.Pat. No. 5,553,730 to be realized while also minimizing the need forextensive additional inventory of junction boxes.

SUMMARY OF THE INVENTION

The present invention teaches the construction and use of severaldevices for adapting a standard rectangular or other pre-existingjunction box for flush mounting within a curved structure. A separateadapter frame device or separate adapter segment devices, each of whichdevices is engageable with the standard junction box to projectfrontwardly therefrom and includes a front surface portion that iscurved to correspond to the curvature of the retaining structure intowhich the junction box is to be mounted, is provided. A curved faceplate member may also be provided, the face plate member being abuttablyengageable with the adapter devices and likewise formed so as to havethe same curvature as the curved structure into which the junction boxis mounted.

A standard rectangular junction box typically comprises a housingincluding a planar rear wall, vertically planar side walls extendingfrom the rear wall, and horizontally planar top and bottom wallsinterconnecting the rear and side walls and extending therebetween. Thefront portion of the housing member is substantially open but doesinclude a front portion that extends around the perimeter thereof todefine a lip and/or flange portion, sometimes with associated connectortabs. The curved adapter frame device or adapter segment devices includefront and rear portions, the rear portion of each being matablyengageable with the standard junction box. Typically, the adapter framedevice or adapter segment devices may include a rear surface portionthat may be placed in abutment with a flat front flange portion of therectangular junction box housing at selected locations thereon forattachment thereto, such as through the use of any suitable fasteningmeans such as, for example, rivets, nuts and bolts, fold over tabs,fasteners including snap-lock fasteners, cement, glue, welding and/orother fusion or bonding methods. The front portion of each adapterdevice may typically include a front surface which is curved or arcuatein shape to conform to the curvature of the structure in which thejunction box will be mounted. This construction is advantageous overpreviously known constructions in that it enables a standard rectangularjunction box housing to be used within a wide variety of curvedstructures by the simple expedient of attaching appropriately curvedadapter frame or adapter segment devices to the front portion of thestandard junction box housing and by installing the resultingconstruction in the curved structure. Depending upon the fastening meansused, the same standard junction box can be re-configured with otherframe or curved segment devices having different curvatures in the eventof a change in requirements or application. This saves inventory spaceand cost in that a user need not stock a multitude of differently curvedjunction boxes, but, instead, need only stock standard rectangularlyshaped junction boxes which can be used in both conventionalapplications and, with adapter devices, in curved structures asexplained herein, and a variety of adapter devices of differentcurvatures.

Face plate members may also be shaped to be readily attached by suitablemeans to the curved frame or segment devices so as to form a front wallsurface that totally encloses the cavity or space formed within thejunction box, and preferably include a gasket type seal on the innerside portion thereof. Apertures through any of the wall members formingthe standard junction box, and/or the face plate member, can be providedfor receiving wire leads, conduit, or piping therethrough for attachmentor connection purposes. An access panel may also be provided in the faceplate member to facilitate access to the contents of the junction boxwithout removing the entire face plate member. The adapter components,whether consisting of a curved frame device or one or more curvedsegment devices, with or without the associated curved face platemember, may be provided in assembly kit form, and may include means forfastening the components to the junction box housing as well as to acorrespondingly curved face plate member.

The present components are therefore designed to adapt standardrectangular or other pre-existing junction boxes for compatible use withcylindrical concrete piers and other curved structures that requireelectrical wiring or other electrical controls, or controls forplumbing, gas, or other applications, and connections to be associatedtherewith to effect a desired result. Embedding the junction boxassembly, with adapter devices, within a cylindrically poured concretestructure can be accomplished in a manner similar to that described inco-pending U.S. application Ser. No. 08/316,944, now U.S. Pat. No.5,553,730 or by positioning the junction box assembly, that is, astandard junction box with the adapter frame or adapter segment devicesattached thereto, behind a cutout formed in a sonotube form commonlyused to form up such curved structures or piers prior to pouring theconcrete, positioning the face plate member so that it overlaps thesonotube cutout on the exterior thereof, and fastening the face platemember to the adapter segment devices of the front of the junction boxassembly. Various connection or engagement techniques can be employed,including spring clamping and snap-lock techniques, in addition to otherstandard connection techniques. This latter installation method, asdescribed hereinabove, sandwiches the sonotube form between the faceplate member and the junction box and holds the entire junction boxassembly firmly in place while the concrete is poured. Such methodeliminates the necessity for drilling multiple mounting holes throughthe sonotube form and thereby speeds installation. These installationmethods result in a substantially flush mating of the front wall portionof the junction box assembly with the curved concrete structure. Conduitor other wiring or piping connections can likewise be attached to thejunction box, as required, prior to pouring the concrete. Subsequently,after the concrete has hardened, the face plate member can be unfastenedand the sonotube form can be removed, leaving the concrete pier or othercurved structure with the junction box assembly and conduit or otherelectrical, plumbing, or control components embedded therein.

Although it is preferred that the housing member be a standardrectangular junction box, it is recognized and anticipated that therear, front, and side walls associated with the junction box may take ona wide variety of other shapes and angular orientations, and the boxitself, as well as the adapter devices, may be constructed of varioussuitable materials, such as steel, PVC, or other materials. An importantaspect of the present invention is the fact that the curved adapterframe or adapter segment devices and the face plate member are allshaped so as to conform to the curvature of the outer surface of theparticular structure into which the junction box assembly will beembedded when such components are attached to or matably engaged withthe particular standard junction box being used. Several embodiments ofthe present invention illustrating possible variations are disclosed anddiscussed hereinafter. Thus, when a standard junction box is embeddedwithin a cylindrical concrete pier or other curved structure and thecurved adapter or frame or adapter segment devices and the curved faceplate member are attached thereto in accordance with the teachings ofthe present invention, the exposed face plate member will liesubstantially flush with the curved structure's exterior surface. Thisarrangement permits the advantages sought for the junction box inco-pending application Ser. No. 08/316,944 now U.S. Pat. No. 5,553,730to be realized while permitting the use of standard junction boxes, inassociation with appropriate adapter devices, thereby reducing stockingand inventory cost.

It is therefore a principal object of the present invention to providemeans to adapt standard junction boxes for flush mounting withincylindrical concrete piers and other curved structures.

Other objects and advantages of the present invention will becomeapparent to those skilled in the art after considering the followingdetailed specification in conjunction with the accompanying drawings.

Although, for purposes of discussion and illustration, reference ishereinafter made to an electrical junction box and to electrical wiringand conduit, it should be recognized that the junction box could also bedescribed in terms of plumbing or other applications and with regard topiping or other types of conduit and with regard to various types ofcontrols or connection applications.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded perspective view of a preferred embodiment of anelectrical junction box assembly adapted according to the teachings ofthe present invention for use in a curved structure showing the housingmember with curved segments attached to the top and bottom of the frontwall portion thereof in operative position within a typical cylindricalstructure and further showing the present face plate member positionedfor cooperative engagement with the front portion of the junction boxassembly;

FIG. 2 is another exploded perspective view of a typical rectangularelectrical junction box and the present adapter means similar to FIG. 1without reference to a typical cylindrical structure;

FIG. 3 is an exploded perspective view of the junction box assembly ofFIG. 2 showing a gasket type seal member positioned for operativeengagement between the face plate member and the front portion of thejunction box assembly as well as an access panel associated with theface plate member;

FIG. 4 is a perspective view of another embodiment of the presentadapter means wherein curved segments are attached to a junction boxhaving a curved front wall portion so as to adapt the junction box to acurved structure having a different radius of curvature than the one forwhich the junction box was originally designed;

FIG. 5 is a perspective view showing two of the present curved segmentsincorporated within a frame member that may be fastened to a junctionbox, a gasket type seal member being likewise shown in position foroperative engagement between the frame member and the front portion of ajunction box;

FIG. 6 is a perspective view of another embodiment of the present curvedsegment members incorporated within a frame member that may be attachedto a junction box to extend the depth of such junction box;

FIG. 7 is a top plan view of a typical rectangular junction boxutilizing the present adapter means positioned within a sonotube form,the junction box assembly being held in place prior to the concretepouring by fastening the face plate member via holes in the sonotubeform to the front wall portion of the junction box assembly;

FIG. 8 is a top plan view of another junction box construction showingan alternate housing wall configuration;

FIG. 9 is a top plan view of still another junction box constructionshowing another alternate housing wall configuration;

FIG. 10 is a top plan view of a still further junction box constructionshowing still another housing wall configuration;

FIG. 11 is a perspective view of another typical junction boxconstruction which may be utilized in conjunction with the presentadapter means;

FIG. 12 is an exploded perspective view of another junction box assemblyutilizing still another embodiment of a frame member incorporating thepresent adapter means;

FIG. 13 is a cross-sectional view taken along line 13--13 in FIG. 12;and

FIG. 14 is a partial cross-sectional view similar to FIG. 13illustrating another embodiment of cooperatively engageable means formatingly engaging the frame member of FIG. 12 to the junction boxillustrated therein.

FIG. 15 is an exploded perspective view, generally similar to FIG. 6,but showing a frame as assembled from separable component parts.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to the drawings more particularly by reference numbers whereinlike numerals refer to like parts, number 20 in FIGS. 1 and 2 identifiesa typical rectangular electrical junction box adapted for mountingwithin a curved structure according to the teachings of the presentinvention. FIG. 1 shows the junction box assembly 20 installed in acylindrical concrete pier P. The junction box assembly 20 comprises astandard rectangular junction box housing member 22 which includes arear wall portion 24, spaced side wall portions 26 and 28, a front lip29 which includes a flange portion 30, spaced top and bottom wallportions 32 and 34 extending the full length and depth of the housingmember 22 between the front, rear and side wall portions thereof asshown in FIGS. 1 and 2, and a pair of curved segment members 31 attachedto the front lip 29 which includes a flange portion 30 at selectedlocations as shown. The lip 29 and flange portion 30 extend peripherallyaround the front edge portion of the housing member 22 and, in thisparticular application, the curved segments 31 are attached respectivelyto the top and bottom surface of the front flange portion 30 asillustrated. The front wall or surface portion 33 of each of the curvedsegments 31 includes a radius of curvature substantially equal to thatof the curved structure P into which the entire junction box assembly 20will be mounted. The curved segments 31 further provide a mating surfacefor attachment of the present face plate member 38 as will behereinafter explained.

The housing wall members 24, 26, 28, 30, 32 and 34 define asubstantially enclosed space 36 which forms the interior portion of thejunction box assembly 20 wherein electrical connections and/or controlscan be housed and accessed. This space 36 is easily accessed through thefront flange portion 30 of the housing member 22 as illustrated in FIGS.1 and 2 and is completely enclosed when the face plate member 38 isattached to the junction box assembly 20 as indicated in FIG. 2. Infact, the present curved segments 31, when attached to the front flangeportion 30 of the housing member 22, actually extend the usable space 36within the assembly 20 by the dimensions of the curved members 31.Conduit, conductors or other components may extend into the electricaljunction box assembly 20 through any number of apertures or knockoutsthat can be located, where desired, on any of the wall portionsassociated with the housing member 22 such as the apertures 43, 44 and46 illustrated in FIGS. 1 and 2. These apertures can be provided throughany of the wall portions including the side wall portions 26 and 28 forattachment to conduit and/or for receiving wiring leads depending uponthe particular application. Any aperture that remains open afterconduit, wiring or other components have been installed within the space36 may be plugged or sealed so that excess concrete or otherconstruction materials do not leak into the housing member 22 during thecasting process.

The curvature of the convex front wall portion 33 of each of the curvedsegments 31 is fashioned so as to correspond to the curvature of theouter surface of the curved structure or cylindrical pier P as shown inFIG. 1. It is important to attach the curved segments 31 to the top andbottom portions of the front flange portion 30 of the housing member 22as best illustrated in FIG. 2 before mounting the entire assembly 20within the cylindrical or curved structure P so that the junction boxassembly 20 will be substantially flush with the exterior surface of thecurved structure into which it is embedded as illustrated in FIG. 1. Thecurved segments 31 may be attached to the front flange portion 30 byusing any suitable fastening means including, without limitation,screws, nuts and bolts, rivets, fold over tabs, snaplock fasteners,welding, bonding cement, glue, or other suitable means. By making thecurved segments 31 attachable to standard rectangular junction boxes,inventory requirements are substantially reduced since only therectangular junction boxes and the curved segments such as the members31 need be stocked instead of stocking both planar and curved-frontjunction boxes. A further advantage is that, in the event of a change inthe curvature of the mounting structure, a different curved segment maybe selected for attachment to the same housing member 22 rather thanscraping the previously fashioned curved unit and constructing a totallynew curved junction box as would be required with a junction boxconstructed according to the teachings of the co-pending U.S.application Ser. No. 08/316,944 now U.S. Pat. No. 5,553,730.

With respect to the housing member 22, flange portion 30 is preferablydimensioned so that at least a portion of the curved segment member 31may be attached or otherwise fastened to it. In the embodiment shown inFIG. 2, the front flange portion 30 is substantially planar and thecurved segments 31 include a substantially flat rear wall 35 that isshaped and dimensioned to lie substantially flush with the top andbottom surface portions of the front flange portion 30 therebyfacilitating attachment thereto. The curved segments 31 are attachableto the top and bottom of the front portion 30 by suitable means aspreviously explained to form an enclosure with the housing structure 22when the face plate member 38 is attached thereto.

The face plate member 38 is likewise convex or otherwise curved orrounded to correspond to the radius of curvature associated with thecurved segment members 31, and, accordingly, to the curvature of theouter surface of the retaining structure P. The face plate member 38also preferably includes a gasket type seal member 39, as shown in FIG.3, on the inner side portion thereof and is adapted to be attached byany suitable attachment means to at least a portion of the front flangeportion 30 as well as the curved segments 31 such as by the fastenermeans 40. When attached to the front flange portion 30 and the curvedsegments 31, the gasket seal 39 located on the concave side of the faceplate member forms a tight weatherproof seal therebetween therebyfurther protecting the contents of the junction box assembly 20 fromdeterioration and other problems associated with exposure to theelements. Likewise, since the junction box assembly 20 is recessedwithin the curved structure P, it provides greater protection to thecontents thereof and greatly decreases its exposure to damage from awide variety of other external sources, including unwanted tampering.The fastener means 40 may be such that they are not easily removable tofurther deter unwanted tampering, in which case an access panel such asthe panel member 41 associated with face plate member 38' (FIG. 3) maybe provided in the face plate member to allow entry into the innerportion of the junction box assembly 20 and the wires and othercomponents located therein. The access panel 41 may also includesecurity means such as a lock mechanism 42 to prevent unauthorizedaccess and such panel 41 may be pivotally attached as shown in FIG. 3for easy access to the enclosed space 36.

Another anticipated embodiment as shown in FIG. 4 includes a junctionbox 47 with a curved front portion constructed according to theteachings of co-pending U.S. application Ser. No. 08/316,944, now U.S.Pat. No. 5,553,730, with curved segments 48 attached thereto to adaptthe preconstructed junction box 47 to a structure having a differentcurvature than the one for which the junction box 47 was originallydesigned. In this case, as shown in FIG. 4, each of the curved segments48 includes an inner concave rear surface portion 49 which is formed tolie substantially flush with the curved front wall portions 50 ofjunction box 47 when positioned thereagainst, and an outer convex frontsurface portion 51 which is shaped so as to conform to the curvature ofthe outer surface of the curved retaining structure when the entirejunction box assembly is embedded in the retaining structure. Thecurvature of the concave rear portion 49 of each of the segment members48 corresponds to the curvature of the front wall junction box portions50 whereas the curvature of the convex front portion 51 of each of thesegment members 48 corresponds to the curvature of the outer surface ofthe curved retaining structure such as the cylindrical concrete pier Pillustrated in FIG. 1. The curved members 48 may be attached to thecurved front wall portions 50 of the junction box 47 by using anysuitable means similar to the attachment of curved members 31 toselected portions of the front flange portion 30 of housing member 22.

Referring again to FIG. 2, when the curved segments 31 are attached tothe housing member 22, the exposed side portions 30A and 30B of thefront flange portion 30 remain substantially planar as illustrated.Thus, when the face plate member 38 is attached to the curved segments31, only the edges of the side portions 30A and 30B come into contactwith the face plate member 38. In situations where a weatherproof sealis important, increased surface contact between the side portions 30Aand 30B and the face plate member 38 may be necessary to properly retainthe weatherproof gasket. When this situation arises, a frame member 52as shown in FIG. 5 may be utilized for attachment to the housing toprovide a better seal between the respective mating surfaces. The framemember 52 includes two curved segments 53 and two curved or slanted sideframe portions 54. The curved segments 53 can be constructed along thesame lines as the members 31 or 48 depending upon the construction ofthe particular junction box being utilized. The slanted or curved sideframe portions 54 are likewise similarly curved so as to conform to thecurvature of the segments 53 and such side portions will provideincreased contact with the side edge portions of the face plate memberwhen positioned thereagainst thereby presenting more surface area forretaining a weatherproof gasket such as the gasket member 39. It is alsoimportant to recognize that the frame member 52 may be constructed so asto be utilized with any junction box such as the junction box housings22 and 47 as previously indicated. In the case of housing 22, the sideframe portions 54 are constructed so as to mate and lie flush with thehousing side portions 30A and 30B whereas in the case of housing 47, theside frame portions 54 are constructed to mate and lie flush with thehousing side portions 50A and 50B. Still further, an additional gasketmember such as the gasket member 55 illustrated in FIG. 5 may bepositioned and attached between the front wall portion of the junctionbox housing and the frame member 52 to provide still greater protectionfrom the elements.

FIG. 6 illustrates yet another embodiment of a frame member 56incorporating curved segments 57 and side extension panels 58, suchframe member being shaped to increase the depth of the overall junctionbox assembly. By attaching a frame assembly such as frame member 56 to astandard junction box, added space becomes available within the housingfor additional wiring or other materials for which there may otherwisebe insufficient space. The side extension panels 58 may also include acurved or slanted section 59 toward the front portion thereof forincreased surface contact with a face plate member attached thereto suchas the face plate members 38 and 38' illustrated in FIGS. 2 and 3. Theframe member 56 may be comprised of multiple components fastenedtogether by suitable means or, alternatively, the frame member 56 may beformed by any molding or forming process that produces a one-piececonstruction.

It is anticipated that the various present components for adapting astandard rectangular or other pre-existing junction box for flushmounting within a curved structure may be packaged in assembly kits andprovided to customers who require the advantages of a junction box thatis shaped to achieve a flush mount within a curved structure. The kitsconsisting of various combinations of the present components such as theframe members 52 and 56 as illustrated in FIGS. 5 and 6, or the curvedsegments 31 and 48 as shown in FIGS. 2 and 4, and/or the face platemembers 38 and 38', along with means for attaching the right combinationof such members to the junction box assembly would be particularlyuseful where a customer has an existing supply of standard rectangularor curved-face junction boxes, and a requirement for installing themwithin a wide variety of curved structures. The kits would includesuitable instructions so that any non-skilled person, with minimum toolrequirements, could easily adapt an existing junction box for mountingin a curved retaining structure.

The present means for adapting a junction box for use within curvedstructures is specifically designed to facilitate casting within acylindrical concrete pier or other curved structure and allow thejunction box assembly to be easily positioned and retained in its properlocation during the forming process as shown in FIG. 7. In this regard,the junction box assembly 20 can be easily inserted through andpositioned adjacent to a cutout 62 located in a sonotube form 60, whichsonotube forms are typically used in forming a wide variety of differenttypes of concrete piers that are used in a multitude of differentapplications such as a base for light poles and other structures. Thejunction box assembly 20 can be positioned and supported in its desiredlocation using the arrangement shown in FIG. 7 or other means sufficientto keep the overall junction box assembly 20 stable and steady duringthe pouring process. As shown in FIG. 7, the junction box assembly 20includes a pair of curved segments such as the segments 31 attached to atypical rectangular electrical junction box such as the junction box 22and the entire assembly 20 is secured within the sonotube form 60 priorto the actual pouring of any concrete by positioning the assembly 20inside of the form 60 and adjacent to the cutout 62 as illustrated andthereafter positioning the face plate member 38 over the cutout 62 onthe outer surface of the sonotube form 60. The face plate member 38 isthen fastened to the junction box assembly 20 using fastening means,such as the threaded fasteners 40, which are threadedly positionedthrough aligned holes located in the face plate member 38, the sonotubeform 60, the curved segments 31, and/or the front wall side portions 30Aand 30B of the housing member 22. In the case where the frame member 52or 56 is utilized to form the junction box assembly 20 of FIG. 7, thealigned holes are drilled or otherwise formed around the outsideperiphery of such frame member. Once the face plate member 38 is securedto the assembly 20, a portion of the sonotube form 60 is sandwichedtherebetween and provides sufficient rigidity and stability to hold theassembly 20 in proper position during the casting process. Once theconcrete material is cured and set, the junction box assembly 20 will befirmly embedded therewithin. Conduit, wiring and/or other controls forplumbing, gas or other applications can be attached to the junction boxassembly 20, as required, prior to the pouring process and suchinstallation would also help prevent the junction box assembly 20 frombecoming dislodged from its encasement. Subsequently, the face platemember 38 can be unfastened and the sonotube form 60 can be removed,leaving the concrete pier with the junction box assembly 20 andconduit/wiring/controls encased therein. As an additional precaution,means such as tabs, flanges or ridges may also be employed on the top,bottom and/or side walls of the junction box assembly 20 to furtherprevent such assembly from being moved or otherwise dislodged from itsproper position.

Although the shape and configuration of the housing member 22illustrated in FIGS. 1 and 2 is most generally used, it is important torecognize that the present means for adapting a conventional rectangularor other pre-existing junction box housing for mounting within a curvedstructure can be utilized on junction boxes fashioned into a variety ofother sizes and shapes without impairing the teachings and practice ofthe present construction. For example, the planar side walls 66 and 68associated with the housing embodiments 64 and 65 illustrated in FIGS. 8and 9 may be angled inwardly as shown, or, as illustrated in FIG. 10,the side walls 70 and 72 may extend in a substantially paralleldirection relative to each other between the front and rear wallportions 74 and 76. The substantially planar rear wall portion 24associated with housing 22 as illustrated in FIGS. 1 and 2 mayalternatively be formed by a curved rear wall 76 or 78 as shown in FIGS.9 and 10. The rear and side wall portions of the housing member may takeon still other shapes not illustrated herein which will likewise becompatible for use with the particular installation involved.Irrespective of the particular shape and configuration of the front,rear and opposed side wall portions associated with the housing member,it is important that the curved segments 31 and 48 as well as the faceplate members 38 and 38' be curved so as to mount flush or nearly flushwith the curved surface of the encasing structure as best illustrated inFIGS. 1 and 7.

FIGS. 11-14 illustrate still additional uses and embodiments of thepresent adapter means in conjunction with conventional junction boxassemblies wherein no front flange portions such as the flange portions30 and 50 associated with housings 22 and 47 (FIGS. 2-4) areincorporated into the particular junction box to be adapted for flushmounting in a cylindrical or curved shaped structure. More particularly,the junction box 80 illustrated in FIG. 11 includes a rear wall portion82, spaced side wall portions 84 and 86, spaced top and bottom wallportions 88 and 90 extending the full length and depth of the junctionbox 80 between the rear and side wall portions thereof, a front lip oredge portion 92 which extends around the entire front periphery of thejunction box 80, and a plurality of tabs or flange portions 94 which arepositioned at selected locations along the front lip 92 so as to extendinwardly towards the center of the junction box 80 as illustrated inFIG. 11. In this particular embodiment, a pair of tab members 94 areassociated with the front lip 92 of each of the top and bottom wallportions 88 and 90 as illustrated. Each of the tab members 94 includesan opening or aperture 96 for receiving a threaded member therethroughand such tab members 94 are specifically provided as means for attachingthe curved segments of the present invention such as the segments 31 and48 to the top and bottom edge portions 92 of the junction box 80. Inthis regard, the curved segments such as the segments 31 are attachedrespectively to the top and bottom edge portions 92 of wall portions 88and 90 by positioning suitable fastening means through the apertures 96located in each of the tab members 94, and through aligned apertureslocated through the rear wall portion of each of the curved segments andthereafter securing the same. Since the junction box 80 does not includea front flange portion such as the flange portion 30 illustrated inFIGS. 2 and 3, the tab members 94 provide the necessary means forsecurely attaching the curved segments of the present invention to thetop and bottom front lip portions of a typical junction box 80. Once thecurved segments of the present invention are suitably secured to thejunction box 80, all other components of the present invention such asthe face plate members 38 and 38' and the gasket member 39 illustratedin FIGS. 2 and 3 can be positioned and attached as previously described.It is also important to recognize that the position and location of therespective tab members 94 and well as the total number of such membersmay vary from one application to another, the only requirement beingthat a sufficient number of such tab members be utilized as to properlysecure and stabilize the respective curved segments to the junction box80.

FIG. 12 illustrates still another embodiment of a frame member 98 whichis specifically designed for matably engaging a junction box such as thejunction box 80' wherein the front portion of such junction box isdefined by a peripheral lip or edge portion 92 only. The junction box80' is substantially identical in all respects to the construction ofthe junction box 80 except that the junction box 80' does not includethe tab members 94. Like the frame member 52, the frame member 98includes two curved segments 100 and two side frame portions 102. Thecurved segments 100 are substantially similar to the curved segments 53of frame member 52 and are constructed so as to conform to the curvatureof the curved structure into which it will be embedded. The frontsurface portion of each of the side frame portions 102 may likewise besimilarly curved so as to conform to the curvature of the frame segments100 and each such side frame portion 102 is substantial U-shaped inconstruction as best illustrated in FIG. 13, the space 104 defined bythe U-shaped construction of the side frame portions 102 beingsufficiently dimension so as to insertably receive therewithin the frontlip 92 and a portion of each of the opposed side wall portions 84 and 86of junction box 80'.

Each side frame portion 102 further includes spring biasing engagementmeans 106 extending into the space 104 as best shown in FIG. 13, thebiasing means 106 engaging the corresponding side wall portions 84 and86 of the junction box 80' when said side wall portions are positionedwithin the space 104. The spring biasing means 106 may take on a widevariety of different configurations including a single biasing meansextending the full length of each side frame portion 102; it may includea plurality of spring biasing members 106; and/or it may include springbiasing means projecting into the space 104 from each opposite side ofthe U-shaped construction, the only requirement being that such springbiasing means sufficiently engage the junction box side wall portions 84and 86 so as to sufficiently hold the frame member 98 in proper positionand engagement with the junction box 80'. It is also anticipated andcontemplated that other biasing arrangements may likewise be utilized.

It is also contemplated that other engagement means such as a snap-lockfitting arrangement may be utilized instead of spring biasing means tosufficiently hold the frame member 98 in engagement with the junctionbox 80'. In this regard, FIG. 14 illustrates one type of snap-lockarrangement suitable for use with the present invention wherein theopposed side wall portions of the junction box such as the side wall 84illustrated in FIG. 14 includes an offset portion or projection 108 andone of the arms forming the U-shaped construction of the correspondingside frame portion 102 such as the side arm 110 (FIG. 14) includes acorresponding offset or projection 112. When the junction box side wall84 is inserted in the space 104, the wall projection 108 willsufficiently deflect side frame arm portion 110 and expand space 104 soas to allow the projection 108 to slip behind the arm projection 112 asshown in FIG. 14 thereby engaging the same and preventing the framemember 98 from being easily disengaged from the junction box 80'. Hereagain, the snap-lock means 108 and 112 may be fabricated in a widevariety of different configurations such as including a single side walloffset or projection 108 extending the full length of each junction boxside wall 84 and 86 along with a corresponding arm projection 112likewise extending the full length of side frame arm portion 110, orsuch projections 108 and 112 can be formed into a plurality ofprojections extending in space apart relationship the full length of thecorresponding wall and arm portions 84, 86, and 110. Other snap-lockengagement means are likewise possible.

Still further, it is likewise anticipated and contemplated that the rearportion of each of the two curved segments 100 associated with framemember 98 may likewise be constructed so as to include meanscooperatively engageable with the front lip or edge portion 92associated with the top and bottom wall portions 88 and 90 of thejunction box 80' substantially similar to the construction of the sideframe portions 102 and the spring biasing means 106 (FIG. 13) or thesnap-lock means 108 and 112 (FIG. 14) utilized in conjunction therewith.A face plate member similar to plate members 38 and/or 38' may bethereafter attached to the frame member 98 as previously explained.Encasement of the junction box 80' with the frame member 98 engagedtherewith within a cylindrical concert pier or other curved structurewill further prevent disengagement of such members from each other. Itis also recognized that the junction boxes 80 and 80' along with thevarious components of the present invention as discussed with respect toFIGS. 11-14 including the frame member 98 may be positioned and retainedin its proper location during the forming or casing process in the samemanner as discussed with respect to encasement of the junction boxassembly 20 illustrated in FIG. 7. Other variations are likewisepossible.

It is therefore recognized and anticipated that the present junction boxassemblies as illustrated in FIGS. 1-14 may be used in many differenttypes of curved structures including curved structures fabricated from awide variety of materials other than concrete. It is also anticipatedand recognized that the frame members 52, 56 and 98 illustrated in FIGS.5, 6 and 12-14 may be formed from a single sheet of material pressedinto the desired shape thereby further increasing their strength anddurability as well as improving the weatherproof and tamperproofcapabilities of the present assembly. Still further, it is alsoimportant to note that the overall dimensions of any of the presentjunction box assemblies such as the assembly 20 illustrated in FIG. 1,including the face plate members 38 and 38', as well as the particularconfiguration of the rear and side walls associated with the housingmember are subject to wide variations as previously explained. Althoughthe present junction box assemblies have particular utility and arereadily employable in cylindrical concrete piers, such assemblies canlikewise be utilized in a multitude of different applications, includinguse in a wide variety of other curved structures.

Thus, there has been shown and described a novel means for adapting ajunction box for ready use in curved structures, which junction boxassembly fulfills all of the objects and advantages sought therefor.Many changes, modifications, variations and other uses and applicationsof the present constructions will, however, become apparent to thoseskilled in the art after considering this specification and theaccompanying drawings. All such changes, modifications, variations andother uses and applications which do not depart from the spirit andscope of the invention are deemed to be covered by the invention whichis limited only by the claims which follow.

What is claimed is:
 1. Means for adapting a junction box for mountingwithin a curved structure wherein said junction box defines an interiorspace and includes a front wall portion which is substantially open andprovides access to the interior space of said junction box, said meanscomprising a frame member having top, bottom and opposed side portions,said frame member being sized and dimensioned so as to correspond andmate with the front wall portion of said junction box, the top andbottom portions of said frame member each having a front surface portionwhich is curved so as to conform to the curvature of the outer surfaceof the curved structure into which said junction box will be mounted,and means for attaching said frame member to the front wall portion ofsaid junction box.
 2. The means defined in claim 1 including a faceplate member attachable to said frame member for controlling access tothe interior space of said junction box, said face plate member beingsimilarly curved so as to conform to the curvature of the top and bottomportions of said frame member, and means for attaching said face platemember to said frame member.
 3. The means defined in claim 2 whereinsaid face plate member includes an access panel to allow access to theinterior space within said junction box.
 4. The means defined in claim 1wherein the side portions of said frame member are similarly curved soas to conform to the curvature of the top and bottom portions of saidframe member.
 5. Means for adapting a junction box for substantiallyflush mounting within a curved structure, the junction box forming anenclosure and having a peripheral wall defining an interior space withinthe junction box and a front surface portion defining a front lipsubstantially surrounding a front opening to permit access to theinterior space of the junction box, said means for adapting a junctionbox comprising an adapter construction configured to be engageable withthe junction box and including a protruding peripheral portion whichprojects forwardly from the front surface portion of the junction boxwhen the adapter construction is engaged with the junction box todefine, in conjunction with the peripheral wall of the junction box, anexpanded enclosure that includes the interior space of the junction box,said adapter construction having a front portion curved so as to conformto the curvature of the outer surface of the curved structure, and meansfor maintaining said adapter construction in matable engagement with thejunction box.
 6. The means defined in claim 5 wherein said adapterconstruction includes a frame device having outer sides which define aconfiguration that conforms to the configuration defined by theperipheral wall of the junction box.
 7. The means defined in claim 6wherein the front lip of the junction box includes a flange portion andwherein said adapter construction includes a rear surface configured toabut the flange portion of the junction box, said means for maintainingsaid adapter construction in engagement with the junction box includingmeans for attaching said frame member to the flange portion of thejunction box.
 8. The means defined in claim 5 wherein said peripheralportion of said adapter construction includes a pair of curved segmentdevices each having a front exterior portion curved so as to conform tothe curvature of the outer surface of the curved structure and a pair ofside framing segments extending between and interconnecting said curvedsegment devices to define a frame structure, said front exteriorportions of said curved segment devices each being part of said frontportion of said adapter construction.
 9. The means defined in claim 8wherein said adapter construction is an integral unit.
 10. The meansdefined in claim 5 wherein the front lip of the junction box includes aflange portion and wherein said adapter construction includes a rearsurface configured to abut the flange portion of the junction box at atleast portions thereof.
 11. The means defined in claim 10 wherein saidadapter construction is an integral unit including a pair of curvedsegment portions each having a front exterior portion curved so as toconform to the curvature of the outer surface of the curved structure,said front exterior portions of said curved segment portions each beingpart of said front portion of said adapter construction.
 12. The meansdefined in claim 10 wherein said adapter construction is a frame memberhaving top, bottom, and opposed side portions, said top and bottomportions each having a front surface portion forming at least a portionof said front portion of said adapter construction, said side portionsextending between and interconnecting said top and bottom portions. 13.The means defined in claim 5 wherein said peripheral portion of saidadapter construction includes a pair of curved segment portions eachhaving a front exterior portion curved so as to conform to the curvatureof the outer surface of the curved structure, said front portion of saidadapter construction including said front surface portions of saidcurved segment portions.
 14. The means defined in claim 13 wherein saidadapter construction includes an interconnection portion extendingbetween and interconnecting said pair of curved segment portions tospace said pair of curved segment portions from one another.
 15. Themeans defined in claim 14 wherein said adapter construction is a unitaryconstruction.
 16. The means defined in claim 14 wherein saidinterconnection portion includes a pair of side frame portions.
 17. Themeans defined in claim 16 wherein said pair of curved segment portionsand said pair of side frame portions define an integral member.
 18. Themeans defined in claim 16 wherein said pair of curved segment portionsand said pair of side frame portions define a frame assembled fromseparable component parts.
 19. A junction box adapter for adapting ajunction box for mounting within a curved structure wherein the junctionbox defines an interior space and includes a front which issubstantially open and provides access to the interior space of thejunction box, said junction box adapter comprising a junction box facingmember having top, bottom and opposed side portions, said junction boxfacing member being sized and dimensioned so as to correspond and matewith the junction box, the top and bottom portions of said junction boxfacing member each having a front surface portion which is curved so asto conform to the curvature of the outer surface of the curved structureinto which said junction box will be mounted, and means for attachingsaid junction box facing member to the junction box.
 20. A junction boxadapter for adapting a junction box for mounting within a curvedstructure wherein the junction box defines an interior space andincludes a peripheral wall and a front which is substantially open andprovides access to the interior space of the junction box, said junctionbox adapter comprising a junction box facing member having a perimeterportion configured to abut the peripheral wall of the junction box nearthe front thereof and to mate with the junction box, said junction boxfacing member having a front surface portion which is curved so as toconform to the curvature of the outer surface of the curved structureinto which said junction box will be mounted, and means for attachingsaid junction box facing member to the junction box.
 21. A kit foradapting a junction box having a front wall portion for mounting withina curved structure such that the front of the resulting constructionconforms substantially to the curvature of the outer surface of thecurved structure, said adapting kit comprising(a) a frame member havingtop, bottom and opposed side portions, said frame member being sized anddimensioned so as to correspond and mate with the front wall portion ofsaid junction box, the top and bottom portions of said frame member eachhaving a front surface portion which is curved so as to conform to thecurvature of the outer surface of the curved structure into which saidjunction box will be mounted, (b) means for attaching said frame memberto the front wall portion of said junction box, (c) a face plate memberattachable to said frame member for controlling access to the interiorspace of said junction box, said face plate member being similarlycurved so as to conform to the curvature of the top and bottom portionsof said frame member, and (d) means for attaching said face plate memberto said frame member.
 22. The kit defined in claim 21 including a gasketmember, said gasket member being positionable between said face platemember and said frame member when said face plate member is attachedthereto.
 23. The kit defined in claim 21 wherein said face plate memberincludes an access panel to allow access to the interior space of saidjunction box.